Connecting component

ABSTRACT

A connecting component connecting two members, such as a suspension component and a vehicle component, dampens vibrations and produces springing forces. The connecting component is formed by a steel strip including a plurality of holes. A sealing strip is secured to the upper surface of the steel strip to contain fluid for damping, and springing strips are secured to the upper surface of the steel strip to provide for springing forces. The steel strip is rolled to form the connecting component, trapping the fluid between the sealing strips. As the connecting component is a linking element with several degrees of freedom, different springing and damping rates are possible at each degree of freedom.

BACKGROUND OF THE INVENTION

[0001] The present invention relates generally to a method for buildinga connecting component which produces variable damping and springingforces.

[0002] A suspension system absorbs road shock and other vibrations,while providing for a smooth and comfortable ride. The suspension systemresponds to wheel disturbances and reacts to maintain wheel contact withthe road surface.

[0003] Damping systems are commonly employed in vehicles to produceopposing forces which counteract vibrations produced during vehicleoperation. Suspension systems provide damping and springing forces tocancel resonant responses that cause unwanted motion. In priorsuspension systems, fluid filled shock absorbers counteract thesevibrations. As fluid is commonly utilized to provide damping, thedamping force increases approximately proportionally with the viscosityof the damping fluid. A drawback to prior damping systems is that theseshock absorbers are passive in nature.

[0004] A connecting component, such as a bushing, is commonly utilizedin a vehicle suspension system to connect a suspension component, suchas a stabilizer bar, to a vehicle component. One drawback to prior artconnecting component is the inability of the connecting component tovary the damping and springing forces, especially at different locationsof the connecting component.

[0005] Hence, there is a need in the art for an improved connectingcomponent which produces variable damping and springing forces.

SUMMARY OF THE INVENTION

[0006] This invention relates to a method for building a connectingcomponent which produces variable damping and springing forces.

[0007] The connecting component of the present invention is formed by asteel strip including a plurality of holes. A continuous sealing strippositioned on the upper surface of the steel strip inside the perimetercontains a fluid which provides damping, and springing strips positionedinside the sealing strip provide springing forces. As the steel strip isrolled to form the connecting component, fluid dispersed on the uppersurface of the steel strip by a fluid disperser is contained andsubstantially trapped within the sealing strip. When the rolling iscomplete, a connecting component is formed with a substantially spirallyshaped interior structure.

[0008] The connecting component connects and transmits force between twomembers, preferably a stabilizer bar of a suspension system and avehicle component. Relative movement or springing is provided by theelastic springing strips, while vibration attenuation or damping isprovided by the fluid passing through the holes. The connectingcomponent is a linking element with several degrees of freedom, anddifferent springing and damping rates are possible at each degree offreedom due to this invention. The characteristics of the connectingcomponent can be altered by changing the distribution of the elasticspringing strips and the holes.

[0009] When a force acts on the connecting component, the elasticspringing strips under the force are compressed, expanding surroundingspringing strips and allowing for springing. Fluid is forced through theholes from the area being compressed to the area being expanded,producing a damping effect. The connecting component allows for rotationand displacement while at the same time providing for springing anddamping of vibrations.

[0010] In one embodiment, the fluid may be electro-rheological fluid ormagnetic-rheological fluid. Piezo-elements located on a load carryingmember, such as a spring, energize and alter the state of the fluid inthe connecting component, allowing for further control of the relativestiffness of the connecting component.

[0011] Accordingly, the present invention provides a method for buildingconnecting components which produces variable damping and springingforces.

[0012] These and other features of the present invention will be bestunderstood from the following specification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The various features and advantages of the invention will becomeapparent to those skilled in the art from the following detaileddescription of the currently preferred embodiment. The drawings thataccompany the detailed description can be briefly described as follows:

[0014]FIG. 1A illustrates the connecting component utilized to connect asuspension component to a vehicle component;

[0015]FIG. 1B schematically illustrates the connecting componentutilized to connect a member to a vehicle component;

[0016]FIG. 1C schematically illustrates the connecting componentutilized on a bumper;

[0017]FIG. 2 illustrates a perspective view of the steel sheetperforated with a plurality of holes;

[0018]FIG. 3 illustrates a perspective view of the steel sheet with thesealing strips;

[0019]FIG. 4A illustrates a perspective view of the steel sheet with thespringing strips in a first orientation;

[0020]FIG. 4B illustrates a perspective view of the steel sheet with thespringing strips in a second orientation;

[0021]FIG. 4C illustrates a perspective view of the steel sheet with thespringing strips in a third orientation;

[0022]FIG. 4D illustrates an additional layer of springing materialemployed on the steel strip;

[0023]FIG. 5 illustrates a perspective view of the steel sheet with theplurality of holes along length X and Y bonded with a sealing material;

[0024]FIG. 6 illustrates a side view of the steel sheet at the firststage of rolling;

[0025]FIG. 7A illustrates an enlarged view of the loop showing a firsttype of attachment of an edge of length X to the steel sheet;

[0026]FIG. 7B illustrates an enlarged view of a loop showing a secondtype of attachment of and edge of length X to the steel sheet;

[0027]FIG. 7C illustrates an enlarged view of a loop showing a thirdtype of attachment of an edge of length X to the steel sheet;

[0028]FIG. 8 illustrates a side view of the connection component duringrolling;

[0029]FIG. 9 illustrates a side view of the connecting component afterrolling;

[0030]FIG. 10 illustrates the connecting component being compressed;

[0031]FIG. 11A illustrates a side view of the springing strips on thesteel strip in a first orientation;

[0032]FIG. 11B illustrates a cross sectional view of the connectingcomponent formed by the steel strip of FIG. 11A;

[0033]FIG. 12A illustrates a side view of the springing strips on thesteel strip in a second orientation;

[0034]FIG. 12B illustrates a cross sectional view of the connectingcomponent formed by the steel strip of FIG. 12A;

[0035]FIG. 13 illustrates a top view of active electrical elementsutilized on a load carrying member to supply voltage to the fluid of theconnecting component;

[0036]FIG. 14 illustrates a top view of piezo-elements utilized on aload carrying member to supply voltage to the fluid of the connectingcomponent; and

[0037]FIG. 15 illustrates a side view of the piezo-elements of FIG. 14.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0038]FIG. 1A illustrates the connecting component 23 of the presentinvention employed to connect a suspension component 20 to a vehiclecomponent 21 positioned between and moving with wheels 22. Here thesuspension component 20 may be a stabilizer bar and vehicle component 21may be part of the wheel assembly. The connecting component 23 transmitsforces and movement between the suspension component 20 and the vehiclecomponent 21, while allowing for relative movement through springing andvibration attenuation through damping. The connecting component 23 isinserted into the end 41 of the suspension component 20 and into thevehicle component 21, connecting the suspension component 20 to thevehicle component 21.

[0039] As illustrated schematically in FIG. 1B, the connecting component23 can also be used as a bushing to connect a member 24, such as atorsion bar, a frame rail or seat metal, to a vehicle component 21, herea frame part.

[0040] As illustrated schematically in FIG. 1C, a larger connectingcomponent 23 can also be used in a bumper 51 to absorb impact. Theconnecting component 23 is attached to the vehicle component 21 and ispositioned within the body panel 47. Alternatively, a support member 45can attach the connecting component 23 to the vehicle component 21.

[0041] The following figures will illustrate how the inventionconnecting component 23 may be preferably manufactured.

[0042] As illustrated in FIG. 2, a steel strip 25 having a definedthickness is cut to a desired dimension. A plurality of holes 26 areperforated on the steel strip 25 at defined sites and at a defineddistribution. It is preferred that the steel strip 25 be substantiallyrectangular and include four edges 27 a, 27 b, 27 c, and 27 d. The steelstrip 25 can also be coated for corrosions resistance.

[0043] As shown in FIG. 3, a continuous sealing strip 28 is positionedon the upper surface 30 of the steel strip 25 substantially inside theperimeter 35. The sealing strip 28 is preferably made of rubber and issecured to the steel strip 25 by gluing or bonding. Once positioned, thesealing strip 28 includes four sides 28 a, 28 b, 28 c, 28 d, eachcorresponding to one of the edges 27 a, 27 b, 27 c, 27 d, respectively,of the steel strip 25. Sides 28 a and 28 c of the sealing strip 28 arepositioned at a length X and Y, respectively, away from edges 27 a and27 c of the steel strip 25.

[0044] As shown in FIGS. 4A, 4B and 4C, springing strips 29, preferablymade of rubber, are positioned at a defined distribution, orientationand site on the upper surface 30 of the steel strip 25 inside thecontinuous sealing strip 28. It is preferred that the springing strips29 be positioned substantially parallel or angled to the edges 27 a and27 c of the steel strip 25, as illustrated in FIGS. 4A and 4B,respectively, or be substantially X-shaped, as illustrated in FIG. 4C.It is to be understood that other orientations, shapes and positions ofthe springing strips 29 are possible. As illustrated in FIG. 4D, anadditional layer of springing material 34 can be secured to the lowersurface 33 of the steel sheet 25 to provide providing for additionalspringing.

[0045] As shown in FIG. 5, holes 26 positioned on lengths X and Y,substantially outside of the sealing strips 28 a and 28 c, may be sealedwith a sealing material 37, preferably rubber. Alternatively, the steelstrip 25 can be fabricated without holes 26 on the lengths X and Y.

[0046] As shown in FIG. 6, the length X of the steel strip 25 is nextrolled to create a loop 31 having a first diameter φ_(X). After rolling,it is preferred that the edge 27 a of length X be prebonded to the steelstrip 25. The edge 27 a can be secured to the steel strip 25 in severalmanners. As illustrated in FIG. 7A, a bend 32 could be formed on thesteel strip 25 proximate to the sealing strip 28 a, and the edge 27 abonded directly to the bend 32. As illustrated in FIG. 7B, the edge 27 aof length X is rolled and secured such that the lower surface 33 of thesteel strip 25 is bonded directly to the upper surface 30 of the steelstrip 25. As illustrated in FIG. 7C, the length X can be substantiallytapered at edge 27 a, rather than being a uniform thickness asillustrated in FIG. 7B.

[0047] As illustrated in FIG. 8, the steel strip 25 is then rolledaround first diameter φ_(X), and a viscous fluid F is dispersed from afluid dispenser 39 on to the upper surface 30 of the steel strip 25.This fluid F is substantially trapped on the upper surface 30 betweenthe sealing strips 28 during rolling.

[0048] As shown in FIG. 9, when rolling is completed, the steel strip 25is completely rolled around the first diameter φ_(X) to create thesubstantially spirally shaped connecting component 23. During rolling,the sealing strips 28 and the springing strips 29 are compressed adesired degree, but are not fully compressed to allow for furthercompression when necessary. During rolling it is desired that thediameter φ_(X) be maintained without deformation. Rolling is completedby rolling length Y over the connecting component 23 and securing edge27 c to the lower surface 33 of the steel strip 25 to prevent opening,forming the connecting component 23 of diameter φ_(Y). Edge 27 c ispreferably secured by welding or gluing, although other methods ofattachment are possible.

[0049] The connecting component 23 transmits force between thesuspension component 20 and the vehicle component 21, allowing forrelative movement and vibration attenuation. The springing properties ofthe connecting component 23 are produced by the compression of thespringing strips 29, while damping is produced by the fluid F beingforced to pass through the holes 26. As the connecting component 23 is alinking elements with several degrees of freedom, different springingand damping rates are possible at each degree of freedom. Thecharacteristics of the connecting component 23 can be altered bychanging the distribution of the elastic springing strips 29 and theholes 26.

[0050] As shown in FIG. 10, when a force P acts on connecting component23, the springing strips 29 proximate to force P are compressed. Thefluid F is forced through the holes 26 from the area being compressed Ctowards the area being expanded E, producing damping. Additionally, asthe elastic strips 29 are more compressible than the fluid F, thecompression allows more room for the incoming fluid F. As thedisplacement of the fluid F may produce a small fluid F flow, additionalsmall holes may be necessary in the steel strip 25 to produce the fluidpressure drop necessary for damping. If smaller holes are required, anadditional process step of laser beam drilling can create the holes.However, if less damping is required, the holes 26 in the steel strip 25and the fluid F can be eliminated, the springing strips 29 providing thenecessary damping.

[0051] In one embodiment, the connecting component 23 is utilized as abushing. The springing strips 29 and the holes 26 can be distributed sodifferent axes have different springing and damping characteristics. Inone embodiment, as shown in FIG. 11A, the springing strips 29 are spacedsubstantially equally apart on the upper surface 30 of the steel strip25. When the steel strips 25 is rolled to form the connecting component23, as illustrated in FIG. 11B, the springing strips 29 are randomlypositioned about an axis Z extending substantially along the length ofthe center of the connecting component 23.

[0052] In another embodiment, as illustrated in FIG. 12A, the springingstrips 29 are positioned in a pattern farther part on the upper surface30 of the steel strip 25 in a repeating pattern. When the steel strip 25is rolled to form the connecting component 23 illustrated in FIG. 12B,the springing strips 29 are positioned such that more springing strips29 are positioned along the X-axis, allowing for stiffer springing alongaxis X, and fewer springing strips 29 are positioned along the Y-axis,allowing for softer springing on axis Y. A worker in this art couldeasily determine how to arrange the strips 29 to get the final desiredconfiguration.

[0053] The holes 26 can also be positioned and numbered to correspond toa desired degree of damping. In areas with less holes 26, there isgreater damping, while in areas with more holes 26, there is lessdamping.

[0054] Variations in characteristics on the Z-axis are created byutilizing springing strips 29 of varying shape, such as thesubstantially X-shaped strips illustrated in FIG. 4C.

[0055] Further damping can occur by using electro-rheological ormagnetic-rheological fluid F, as illustrated in FIG. 13. When in theliquid state, the electro-rheological or magnetic-rheological fluid F isflexible and soft. Electrical elements 44, such as capacitors or coils,are located on a load carrying member 52 and connected by a plurality oflead wires 48. A control voltage generated by a power source 46 isapplied to the electrical elements 44 to generate an electric field or amagnetic field, supplying voltage to the connecting component 23 by aconnecting wire 50. The power source 46 is either inside the system oroutside the system, such as a battery. The control voltage increase theviscosity of the fluid F, increasing the relative stiffness of theconnecting component 23.

[0056] Alternatively, as shown in FIGS. 14 and 15, energy converters 34are used to transfer the mechanical energy into electrical energy tocontrol the viscosity of the electro-rheological or magnetic-rheologicalfluid F. When in the liquid state, the electro-rheological ormagnetic-rheological fluid F is flexible and soft. The converters 34 canbe a plurality of piezo-elements 34 mounted to a charge strip 38 on aload carrying member 36, such as a leaf spring, to derive the electricalinput which increases the viscosity of the fluid F and the stiffness ofthe connecting component 23. The piezo-elements 34 are connected by aplurality of lead wires 40. Preferably, the piezo-elements 34 be bondedor glued to the charge strip 38. An increase in load deflects andenergizes the piezo-elements 34 to produce an electrical input,supplying voltage to the connecting component 23 by a connecting wire42, as illustrated in FIG. 14. The electrical input increases theviscosity of the fluid F, increasing the relative stiffness of theconnecting component 23 and producing damping by the opposing forcescreated in the connecting component 23. The voltage signal is related tothe displacement of the suspension and the piezo-element 34 deflectionand provides voltage at desired locations of the connecting component23. The piezo-elements 34 can provide constant voltage to selectedportions of the connecting component 23, allowing for control over thefeel of the ride.

[0057] There are several advantages to utilizing the connectingcomponent 23 of the present invention. For one, damping and springingcan be controlled at different degrees of freedom. Additionally, theconnecting component 23 allows car passengers to experience lessvibrations and shaking. For vehicle manufactures, there is more freedomin design, allowing for lower manufacturing costs. Finally, by usingelectrical elements 44 or piezo-elements 34, there is a higherresistance for damping, allowing for more compensation for largerdisplacements within the connecting component 23. A smaller disturbancecan be reacted to with minimal force. If the connecting component 23 isused in a suspension system, the component 23 can limit body roll.

[0058] The foregoing description is only exemplary of the principles ofthe invention. Many modifications and variations of the presentinvention are possible in light of the above teachings. The preferredembodiments of this invention have been disclosed, however, so that oneof ordinary skill in the art would recognize that certain modificationswould come within the scope of this invention. It is, therefore, to beunderstood that within the scope of the appended claims, the inventionmay be practiced otherwise than as specially described. For that reasonthe following claims should be studied to determine the true scope andcontent of this invention.

What is claimed is:
 1. A method for forming a connecting componentcomprising the steps of: forming a plurality of holes in a sheet;securing a sealing member to an upper surface of said sheet tosubstantially contain a fluid; securing at least one springing member tosaid upper surface of said sheet; applying fluid to said upper surfaceof said sheet; and rolling said sheet to form said substantially spiralshaped connecting component.
 2. The method as recited in claim 1 whereinthe step of securing said at least one springing member includessecuring said at least one springing member substantially inside saidsealing member.
 3. The method as recited in claim 1 wherein the step ofapplying said fluid substantially occurs during the step of rolling. 4.The method as recited in claim 1 further comprising the step of securinga plurality of piezo-elements to a load carrying member, saidpiezo-elements being electrically connected to said connectingcomponent, said fluid being reactive to an electrical input produced bysaid plurality of piezo-elements by a load applied to said load carryingmember.
 5. The method as recited in claim 4 wherein said piezo-elementsapply said electric input to said fluid to substantially alter a stateof said fluid.
 6. The method as recited in claim 1 further comprisingthe step of securing a plurality of electrical elements to a loadcarrying member, said electrical elements being electrically connectedto said connecting component, said fluid being reactive to an electricalinput generated by said plurality of electrical elements which arepowered by a power source, and said plurality of electrical elementsapplying said electric input to said fluid to substantially alter astate of said fluid.
 7. The method as recited in claim 1 wherein thestep of rolling said sheet further includes securing a first end of saidsheet to said upper surface of said sheet to create a loop, continuingrolling said sheet around said loop, and securing an opposing second endof said sheet to a lower surface of said sheet to form said connectingcomponent.
 8. The method as recited in claim 1 wherein compression ofsaid at least one springing member provides a springing force.
 9. Themethod as recited in claim 1 wherein a flow of said fluid through saidplurality of holes provides a damping effect.
 10. A vehicle suspensionsystem comprising: a suspension component; a vehicle component; and aconnecting component to attach said suspension component to said vehiclecomponent, said connecting component including a sheet having aplurality of holes, a fluid applied to an upper surface of said sheet, asealing member secured to said upper surface of said sheet tosubstantially contain said fluid, and at least one springing membersecured to said sheet substantially within said sealing member, saidsheet being substantially rolled into said substantially spiral shapedconnecting component.
 11. The vehicle suspension system as recited inclaim 10 wherein said sheet is made of steel.
 12. The vehicle suspensionsystem as recited in claim 10 wherein said sealing member and said atleast one springing member are made of an elastic material.
 13. Thevehicle suspension system as recited in claim 12 wherein said sealingmember and said at least one springing member are made of rubber. 14.The vehicle suspension system as recited in claim 12 wherein saidsealing member is positioned substantially inside a perimeter of saidsheet.
 15. The vehicle suspension system as recited in claim 12 whereinsaid at least one springing member is substantially linear.
 16. Thevehicle suspension system as recited in claim 14 wherein said at leastone springing member is substantially parallel to an edge of said sheet.17. The vehicle suspension system as recited in claim 15 wherein said atleast one springing member is substantially angled from an edge of saidsheet.
 18. The vehicle suspension system as recited in claim 10 whereinsaid at least one springing member is substantially X-shaped.
 19. Thevehicle suspension system as recited in claim 10 wherein each of said atleast one springing members are positioned substantially equally aparton said upper surface of said steel strip.
 20. The vehicle suspensionsystem as recited in claim 10 wherein each of said at least onespringing members are positioned substantially unequally apart on saidupper surface of said steel strip.
 21. The vehicle suspension system asrecited in claim 20 wherein each of said springing members arepositioned repetitively progressively farther apart on said uppersurface of said steel strips.
 22. The vehicle suspension system asrecited in claim 20 wherein said vehicle suspension system furtherincludes a load carrying member including a plurality of piezo-elements,said plurality of piezo-elements being electrically connected to saidconnecting component to provide an electrical input to said connectingcomponent under a load applied to said load carrying member.
 23. Thevehicle suspension system as recited in claim 22 wherein said appliedelectrical input substantially changes a state of said fluid.
 24. Thevehicle suspension system as recited in claim 22 wherein said loadcarrying member is a leaf spring.
 25. The vehicle suspension system asrecited in claim 22 wherein said fluid is electro-rheological.
 26. Thevehicle suspension system as recited in claim 22 wherein said fluid ismagnetic-rheological.
 27. The vehicle suspension system as recited inclaim 20 wherein said vehicle suspension system further includes a loadcarrying member including a plurality of electrical elements, saidplurality of electrical elements being electrically connected to saidconnecting component to provide an electrical input to said connectingcomponent under a load applied to said load carrying member, saidplurality of electrical elements powered by a power source and saidapplied electrical input substantially changes a state of said fluid.28. The vehicle suspension system as recited in claim 10 wherein saidsuspension component is a stabilizer bar and said vehicle component ispositioned substantially between a pair of wheel.
 29. The vehiclesuspension system as recited in claim 10 wherein said suspensioncomponent is a torsion bar.
 30. The vehicle suspension system as recitedin claim 10 wherein said suspension component is a bumper panel and saidconnecting component attaches said bumper panel to said vehiclecomponent.